Mattress encasement

ABSTRACT

A fabric encasement for a mattress or box spring having an effective amount of a insecticidal diatomaceous earth applied to a bottom and sidewalls of the encasement.

RELATED APPLICATIONS

The present application is a continuation-in-part of PCT Application No. PCTUS18/40585 filed Jul. 2, 2018 which claims priority to the benefit of U.S. Application Ser. No. 62/527,038 filed Jun. 30, 2017, U.S. Ser. Application No. 62/611,211 filed on Dec. 28, 2017 and all of which are incorporated herein by reference.

FIELD OF THE INVENTION

This invention is directed towards a mattress encasement in which a portion of the mattress encasement has an effective amount of diatomaceous earth adhered to the fabric that will provide for insecticide property for bedbugs and other insects.

BACKGROUND OF THE INVENTION

This invention relates to methods of controlling insect populations such as bedbugs that can infect a mattress and bedding materials. In residential and commercial applications, bed beg infestations will frequently occur in bedding, and mattresses and can be difficult to remedy. Heretofore, conventional mattress encasements used to control bedbugs require the use of tightly constructed fabrics that were designed to prevent the entry of bedbugs into the encasement. While such encasement methods may prevent the bedbugs from crawling into the encasement and mattress environment, such encasements do not kill or control the insect populations.

Prior art encasements frequently utilize specialized seams where the mattress encasement is joined together. Such teachings are known in the art as set forth in U.S. Pat. Nos. 8,615,826, 8,938,824 and 10,010,191 all of which are incorporated herein by reference for all purposes.

While the prior art encasements and methods of securing portions of the encasement together may prevent the entry of bedbugs to and from a mattress, such products and techniques do not have any inherent insecticide property to kill and reduce the bedbug population.

Accordingly, there remains room for improvement and variation within the art.

BRIEF DESCRIPTION OF THE DRAWINGS

A fully enabling disclosure of the present invention, including the best mode thereof to one of ordinary skill in the art, is set forth more particularly in the remainder of the specification, including reference to the accompanying.

FIG. 1 is a perspective view of an encasement as contemplated herein;

FIG. 2 is a side plan view of an alternative embodiment of encasement contemplated herein.

SUMMARY OF THE INVENTION

It is one aspect of at least one of the present embodiments to provide for an encasement for a bedding item comprising:

a cover having a top portion, a bottom portion, and a side wall attached between the top and the bottom portions, the top portion being detachable from at least a portion of the side wall or bottom portion;

a zipper operatively disposed between the top portion and one of the side wall portion or bottom portion, wherein the top portion can be removed from the cover;

an effective amount of a diatomaceous earth that adhere to at least one surface of at least one of the side walls or bottom portion of the cover;

wherein the encasement is adapted for securing therein a mattress, a box spring, or a combined mattress and box spring set, diatomaceous earth surface of the cover providing an insecticide property to the encasement.

It is one aspect of at least one of the present embodiments to provide for a process in which diatomaceous earth can be permanently adhered to at least one of a fiber, a fiber containing fabric, articles of manufacture using the fiber and fabric, and foam products such as pillow and bedding wherein an effective amount of diatomaceous earth is secured to the fiber and fabric thereby killing insects that may come in contact with the fabric.

It is a further aspect of at least one embodiment in the present invention to provide a product of a process of applying diatomaceous earth to a molten substrate wherein the diatomaceous earth is partially embedded in the substrate while having a portion of the diatomaceous earth is exposed on the surface of the substrate.

It is a further aspect of at least one embodiment of the present invention to provide for a process and the resulting product of incorporating an effective amount of diatomaceous earth within a fabric mattress encasement having an effective amount of diatomaceous earth within the fabric that will kill insects that come in contact with the fabric.

It is yet another aspect of at least one embodiment of the present, invention to provide for a fabric mattress encasement wherein the diatomaceous earth particle present within the fabric has substantially about at least about 10% of the diatomaceous earth particle exposed, more preferably in a range of 10 to 35% of the diatomaceous earth particle exposed, and more preferably having a range of between 35%-80% of the diatomaceous earth particle exposed.

It is yet another aspect of at least one embodiment of the present invention to provide for a mattress encasement as described above where the diatomaceous earth is present in an amount of at least about 0.2 ounces per square yard.

It is yet another aspect of at least one embodiment of the present invention to provide for a consumer article as set forth above wherein mattress encasement has the diatomaceous earth present on coated surfaces within the cloth of the encasement and at a concentration of about 0.5 ounce per square yard.

It is yet another aspect of a least one embodiment of the present invention to provide for a consumer article having an integral thermoplastic substrate, thermoplastic substrate further comprising one of a yarn, a fiber, foam, fabric, fabric tape, and bedding material.

It is yet another aspect of at least one embodiment of the present invention to provide for a process and a mattress encasement made by the process in which DE is applied to a fabric substrate having a thermoplastic component and comprising the steps of: supplying a fabric substrate having at, least a portion of an exposed surface comprising a thermoplastic material or coating; heating a DE to a temperature above the molten temperature of the thermoplastic material or coating; applying the heated DE to the substrate, the DE adhering to the thermoplastic material or coating and then optionally pressing the substrate to partially embedded the DE into the thermoplastic material.

These and other features, aspects, and advantages of the present invention will become better understood with reference to the following description and appended claims,

DESCRIPTION OF THE PREFERRED EMBODIMENT

Reference will now be made in detail to the embodiments of the invention, one or more examples of which are set forth below. Each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope or spirit of the invention. For instance, features illustrated or described as part of one embodiment can be used on another embodiment to yield a still further embodiment. Thus, it is intended that the present invention cover such modifications and variations as come within the scope of the appended claims and their equivalents. Other objects, features, and aspects of the present invention are disclosed in the following detailed description. It is to be understood by one of ordinary skill in the art that the present discussion is a description of exemplary embodiments only and is not intended as limiting the broader aspects of the present invention, which broader aspects are embodied in the exemplary constructions.

It is to be understood that the ranges mentioned herein include all ranges located within the prescribed range. As such, all ranges mentioned herein include all sub-ranges included in the mentioned ranges. For instance, a range from 100-200 also includes ranges from 110-150, 170-190, and 153-162. Further, all limits mentioned herein include all other limits included in the mentioned limits. For instance, a limit of up to 7 also includes a limit of up to 5, up to 3, and up to 4.5.

As used herein, the term “effective amount” or “about” means the stated value or range, plus or minus 10%, unless a more specific value or range is provided. Formulations which may be listed or claimed as “comprising of” may also be used as formulations listed or claimed as “consisting of”.

In describing any of the various figures or charts or tables herein, the same reference numbers may be used throughout to describe the same material, apparatus, or process pathway. To avoid redundancy, detailed descriptions of much of the apparatus once described in relation to a figure is not repeated in the descriptions of subsequent figures, although such apparatus or process is labeled with the same reference numbers.

The present disclosure relates to protective encasements for bedding items. In one embodiment, contemplated encasements protect bedding items sealed therein from infestation of bedbugs and which have DE as part of the fabric to kill bedbugs and other insects. The encasements of the present disclosure may be used for bedding and or furniture items, including, for example, a mattress, a box spring, a pad, or a cushion. It is further envisioned that encasements of the present disclosure may be used for storage. For example, contemplated encasements may be used for storage of textiles, fabrics, and bedding items includes sheets, mattress covers, blankets, clothing, and the like.

In accordance with this invention, it has been found that at a certain loading level of diatomaceous earth, and where a portion of the DE is exposed on the surface of a fiber or film, the fiber or film can provide for an inhospitable environment for insects such that upon coming in contact with the fiber, fabric, film, or foam, the exposed diatomaceous earth particles will rapidly kill the insect. The materials that can be treated are described in more detail in Applicant's related PCT application PCT/US18/40585 along with loading levels of the diatomaceous earth and which is incorporated herein by reference. The materials to be treated with DE can include extruded fibers, coated fibers, woven fabrics having composite threads or fibers treated so as to have a partially exposed diatomaceous earth particles present and an effective amount and sufficiently exposed to render the diatomaceous earth surface effective for killing insects. Such as ants, bedbugs and fleas. Additionally, non-woven fiber webs and melt blown fabrics can be similarly treated along with film surfaces that are also treated and processed so as to an effective amount of exposed diatomaceous earth secured to the surface of the film.

Diatomaceous earth (DE) is a naturally occurring siliceous sedentary rock that as easily crumbled into a powder form. It typically has a white to off-white powder and a particle size ranging from less than 3 micrometers to more than 1 millimeter but typically is supplied in a range of 10 to 200 micrometers.

For the uses described below, DE can be obtained in a milled or micronized form and typically between 10 micrometers to 50 micrometers and is used for insecticides. Suitable grades of DE can be obtained from a wide, number of supplies. As used herein, it is believed that a food grade DE is suitable for use in the coating processes and the formation of fabric and other materials.

The various methodologies and processes referenced above can be used to apply DE to a thermoplastic surface to create a useful article having at least a portion of the articles exposed surfaces created with an effective amount of diatomaceous earth. As used herein, an effective amount means a loading level and particle size that combines to provide an exposed surface of diatomaceous earth which is partially embedded into a thermoplastic material and which can function as an insecticide for killing insects. The process used to apply the product depends largely on conventional manufacturing processes of the articles to be treated. As seen below, a wide number of coating processes can be utilized based upon the fabric or material to be treated. By the proper selection of loading level, particle size, and the type of application process, including temperature selection and applied pressure, it is found that an effective amount of diatomaceous earth can be provided to a wide number of useful fabrics and substrates, including materials which may be used in the formation of a mattress or box spring encasement.

As referenced above in applicant's co-pending application, methodologies are described that are useful to treat surfaces of thermoplastic polymeric materials that otherwise would not be coated in a separate process. Examples of products made of these materials are fibers and films that are melt extruded. One method takes advantage of introducing DE onto the surface of a fiber or film just as it cools from the molten liquid to solid state. The DE powder is partially embedded to provide permanency for the life cycle of the product and partially exposed to provide an active harsh pesticidal surface.

An alternative method is, to treat fabrics and textile surfaces that are normally coated for a variety of reasons. These include but are not limited to, tensile strength, seam slippage, ravel resistance, hand modification, wear resistance, wear properties, coloration by pigment binding, hydrostatic resistance, porosity control, and stain resistance. These coated textiles include but are not limited to, upholstery fabrics, drapery fabrics, window covering, industrial construction fabrics, bedding fabrics, mattress cover fabrics, bedding foundation fabrics, mattress edging tapes, industrial tape fabrics, wall covering fabrics, carpets, rugs, shelf liners, floor coverings, and tape fabrics. These fabrics and textile materials are most often coated with polymers that are thermoplastic in nature. These polymers can also be used to bond DE powder to surfaces for the purpose of providing a natural insecticide bound to the thermoplastic surface(s).

For example, in one embodiment, encasements contemplated herein may take the form of a mattress or box spring encasement, a garment bag, luggage, storage,containers, animal pillow covers, and the like. In this way, a consumer may further protect themselves and their possessions from parasite infestation, such as bedbugs.

In, another embodiment, encasements of the present disclosure may be factory installed or incorporated into the construction of the bedding item. For example, during manufacture, current box springs are padded, covered with fabric on 5 sides, and a dust cover is stapled to the bottom. It is envisioned that companies that produce box springs for other bedding items would benefit by replacing the conventional fabrics used in box spring manufacture with a bedbug encasement of the present disclosure. In this way, all future box springs would come from the factory with a pre-installed encasement rather than the currently used fabric and dust cover. The perceived advantage may overcome any extra manufacture-associated cost by eliminating the aftermarket installation costs. Such an approach may have even greater advantages for companies that have large scale use of bedding items, such as hotels, cruise ships, and the like.

In one embodiment, as depicted in FIG. 1, an encasement 10 may include a top cover 12, a bottom cover 14, and a sidewall 16 with an opening 18 therein. The top cover 12 and sidewall 16 are joined at an upper seam 20, and the bottom cover 14 and sidewall are joined at a lower 22 seam. The upper 20 and lower 22 seams may be formed by stitching (not shown) or other means known in the art that create impervious joints through which parasites, such as bedbugs may not enter or exit. In some embodiments, knitted fabrics are utilized which may have a dispersion coating on the knit fabrics. Alternatively, the DE can be applied to an adhesive material coating the knit fabric.

One example of such impervious joints includes a stitched seam, including, for example, a French seam. Other contemplated seams may be formed by welding and/or an adhesive. A zipper 24 including complementary first 26 and second 28 zipper tracks and a zipper pull 30 is secured within the opening 18 by known means, such as stitching, to reversibly open and close the opening 18 to allow a bedding item (not shown) to be removably placed within the encasement 10 and sealed therein. While discussed herein in terms of a zipper, the closure for the contemplated encasements may include other suitable means for forming a bedbug proof seal, such as at least one of a hook and loop fastener, an adhesive, an adhesive silicone, a magnet and ferrous material, complementary male and female mating strips of a plastic zipper with or without a slider, and the like. Preferably, the closure mechanisms described herein utilize tight fitting materials and/or the construction that will provide a physical barrier to an entry by bedbugs. Suitable closures are notable in U.S. Pat. Nos. 8,615,826, 8,938,824, and 10,010,191 in which are incorporated herein by reference. Additionally, the fabric components associated with the zipper or closure can also be treated with diatomaceous earth to provide additional insecticidal properties to the encasement.

The opening between the sidewall 16 and top cover 12 as depicted in FIG. 1, will allow bedding items of various sizes, including, for example, a mattress or box spring, to be placed into the encasement 10 when the zipper 24 is completely unzipped and cover 12 is removed. Therefore, various sizes of encasements and openings are contemplated. Further, while the encasement 10 is depicted in FIG. 1 to have a substantially rectangular shape, similar to a mattress or box spring, encasements of the present disclosure may have any desired shape. Still further, encasements may be designed for bedding items based on shape and/or size, including, for example, crib, single, twin XL, full, full XL, queen, and king-sized mattresses, and corresponding box springs.

In yet a further embodiment, encasements may incorporate one or more layers of cushioning associated with at least one of the top layer or the bottom layer. For example, a layer of cushioning may include at least one of a foam, a gel, feathers, a fabric, micro beads, and combinations thereof.

In another embodiment shown in FIG. 2, an encasement 40 may include a top cover 42 and a bottom cover 44 that are joined to each other along a seam 46. The encasement 40 may have an opening 48 between the top 42 and bottom 44 covers through which bedding items or other items for storage may be placed and removed. A zipper 50 including complementary first 52 and second 54 zipper tracks and a zipper pull 56 may be disposed within the opening 48 to reversibly separate top cover 42 from bottom cover 44 to allow an item (not shown) to be placed within the encasement 40 and sealed therein. In this embodiment, a sidewall is not needed.

Materials that may be used for the top cover, bottom cover, and sidewall typically will include one or more of a woven material, a nonwoven material, a fabric, a textile, a plastic, a rubber, a silicone, a foam, a laminate, a leather, and combinations thereof. For example, materials that may be used for the encasements of the present disclosure include cotton, cotton blends, micro fiber, polyester fiber, and polyester fiber blends, recycled textiles, blended textiles, wool, wool blends, lyocell, available as TENCEL® and as LYOCELL BY LENZING®, a cellulose fiber, textiles with an elastic fiber content, silk, silk blends, and combinations thereof. Any desired material or combinations thereof may be used for encasements contemplated herein.

The fabric used for the top cover may be different from or identical to the fabric used for any side panels and/or bottom portion of the encasement. For the parts for the encasement that are treated with DE, the DE material can be present on an exterior of the encasement surface to prevent bedbugs, fleas, ticks, and other insects from crawling onto and into the encasement. In addition, it is also possible to treat the interior surfaces of the various fabric portions such that any insects that were previously present on the mattress or box springs or other inserted item will be exposed to DE when moving within the now confined area of the encasement.

As set forth in Applicant's co-pending application, it is believed useful for fabric to have a treated surface of DE wherein at least above 10% of the DE particle is exposed and more preferably in the range of about 10% to about 35% is exposed. For certain applications, it is believed that a range of up to about 80% of the diatomaceous earth particle may be exposed.

Additionally, it is believed that an effective amount of diatomaceous earth with respect to a mattress encasement is between about 0.1 ounce per square yard to about 0.2 ounces per square yard and more preferably at least about 0.5. However, one of ordinary skill in the art can easily evaluate an effective amount of a diatomaceous earth loading level, such levels being influenced by the percent of the particle which is exposed above the embedded substrate.

In one embodiment, fabric used for the top cover, where contact with a person or animal is more likely, and the bottom cover is bite proof. For example, bedbug bite proof, meaning that a parasite and/or insect, cannot pierce the proboscis through the fabric to reach the person or animal to feed. For example, bedbug bite proof material would prevent the proboscis of the bedbug penetrating through the fabric to reach the person or animal resting thereon. Examples of bedbug bite proof materials that may be used for the encasements of the present disclosure include plastics, rubber, a silicone, and/or leather.

Further examples of bedbug bite proof materials include laminated and/or coated materials. For example, all materials contemplated herein may be laminated and/or with another material to provide a bedbug bite impervious material. In one example, a polyurethane film laminate may be used. Additional laminates and/or coatings are contemplated herein that render the fabric bed hug bite proof. All such materials can have a DE layer(s) on an inner or outer surface as needed.

In another embodiment, it is contemplated that the sidewall may be made out of penetration-proof fabric, meaning this fabric may not necessarily be bite proof, but would still prevent parasites, insects, bedbugs, and the like, from entering or exiting the encasement and provide a DE surface to kill the insects. Further, the material forming the sidewall will help prevent the contents of the encasement from mold or mildew formation while encapsulated by the encasement. In one embodiment, the sidewall is made without a polyurethane lamination or other bedbug bite impervious coating, or only partially laminated and/or coated, or made without airflow restrictive fabrics and/or materials to help ensure proper airflow to prevent mold formation. It is also envisioned that parasite proof vents may be incorporated into the top and/or bottom cover and/or the side walls to help prevent mold or mildew formation and to otherwise keep the encasement contents from acquiring a moldy smell.

The various embodiments described above provide a mattress encasement which has at least one surface of a component part of the encasement treated with diatomaceous earth which provides for encasement which both physically excludes the entry of bedbugs but also provides for a treated surface which will kill the bedbugs. Additionally, the mattress encasement has a removable top which can be washed and replaced while having a least a portion of a side panel or bottom portion treated with diatomaceous earth.

The mattress encasement, in addition to having a diatomaceous earth surface, can be waterproof, fluid proof, or any of the top portions, side panels if present, and/or the bottom surface. The waterproofing and fluid proofing can be achieved using polymeric coating films laminated to a textile surface. At least some of the embodiments, the diatomaceous earth can be applied to the polymeric coatings or films.

Preferably, the mattress encasements can be constructed of tightly woven or formed fabrics which will permit the entry of bedbugs into the encasement and provide at least one exterior surface treated with diatomaceous earth. Additionally, at least one interior surface can also be treated with diatomaceous earth to help control any preexisting population of bedbugs that may be present in a mattress or box spring and which has the mattress encasement subsequently installed.

As seen in one of the embodiments, the mattress encasement may have a fully removable top and/or a portion of the side which can be easily laundered. When so constructed, the remaining portion of a side panel and the bottom of the mattress encasement may be treated with diatomaceous earth on either an exterior and/or an interior surface. By separating the upper portion from the remaining portion of the encasement, the upper portion may be easily laundered and reattached. This is particularly useful in commercial properties such as hotels where frequent laundering of the bed linens is needed and there tends to be a higher rate of bedbug infestation.

Preferably, the mattress, encasement described above used a zipper or other closure mechanism that prevents entry of bedbugs through the zipper or closure when the top is secured to the remainder of the encasement.

In addition to being removable and easily cleaned, the top panel surface of the encasement can be provided from a barrier material that would prevent any bedbug from biting through the, material. This particular feature can be useful for situations where the encasement is used with a mattress or box spring that may have a population of preexisting bedbugs. The barrier top portion will prevent bedbug bites and the ability to treat the interior and exterior surfaces of the bottom and side panels of the encasement will destroy any existing bedbugs as the bedbugs migrate across the treated surfaces.

Although preferred embodiments of the invention have been described using specific terms, devices, and methods, such description is for illustrative purposes only. The words used are words of description rather than of limitation. It is to be understood that changes and variations may be made by those of ordinary skill in the art without departing from the spirit or the scope of the present invention which is set forth in the following claims. In addition, it should be understood that aspects of the various embodiments may be interchanged, both in whole, or in part. Therefore, the spirit and scope of the appended claims should not be limited to the description of the preferred versions contained therein. 

That which is claimed:
 1. A fabric encasement for a mattress or box spring having an effective amount of diatomaceous earth to kill, insects present on exposed surfaces of an encasement bottom, and at least a portion of an encasement side joined to the bottom, the encasement having a top portion that is detachable from the side, the diatomaceous earth having a portion of the diatomaceous earth particles embedded within a thermoplastic component of the fabric of the encasement sides and bottom and an exposed portion of the particle being present above the thermoplastic surface.
 2. The encasement according to claim 1 wherein the diatomaceous earth particle has substantially about at least 10% of the diatomaceous earth particle exposed, more preferably in a range of 10 to 35% of the diatomaceous earth particle exposed, and more preferably the range of between 35%-80% of the diatomaceous earth particle exposed.
 3. The article according to claim 2 wherein the encasement has the diatomaceous earth present in an amount of about 0.1 to about 0.5 ounces per square yard.
 4. The household article according to claim 2 wherein the encasement has the diatomaceous earth is present on a coated surface of the fabric and is present at a concentration of about 0.5 to about 1.0 ounce per square yard.
 5. An encasement for a bedding item comprising: a cover having a top portion, a bottom portion, and a side wall attached between the top and the bottom portions, the top portion being detachable from at least a portion of the side wall or bottom portion; a zipper operatively disposed between the top portion and one of the side wall portion or bottom portion, wherein the top portion can be removed from the cover; an effective amount of a diatomaceous earth for controlling insects that adhere to at least one surface of at least one of the side walls or bottom portion of the cover; wherein the encasement is adapted for securing therein a mattress, a box spring, or a combined mattress and box spring set, the diatomaceous earth surface of the cover providing an insecticide property to the encasement. 